Lesson 1Typical instrumentation and monitoring points: pressure, flow, temperature, contamination sensors, and vibration/noise sensorsThis part defines tools for watching press hydraulics, including pressure, flow, temperature, dirt, vibration, and noise. It explains where to place sensors, their ranges, signal types, and how data helps in checking and predicting maintenance.
Pressure sensor ranges and fitting placesFlow checking for pumps and actuator linesOil heat sensing in tank and key linesDirt counters and clean monitoring spotsVibration and noise sensors on pumps and motorsLesson 2Central hydraulic power unit (HPU) layout: reservoir, pump(s), prime mover, heat exchanger, auxiliary systemsThis part shows central HPU setup for 250-bar presses, explaining tank design, pump and motor setup, suction and return paths, heat exchangers, and support systems for reliable, quiet, and easy-to-service work.
Tank size, barriers, and air removal featuresPump fitting, alignment, and suction line designMain driver choice and connection setupsReturn line paths and foam reduction methodsFitting coolers, filters, and connectorsLesson 3Thermal management: oil-air coolers, flow paths, thermostatic bypass valves, and heat load estimationThis part covers heat behaviour in high-pressure press systems, including heat sources, oil-air cooler choice, flow paths, automatic bypass design, and heat load calculation to keep fluid good and parts reliable.
Heat sources in press hydraulicsHeat load calculation and work cycle checkOil-air cooler size and performance graphsCooler position, flow paths, and pipe setupAutomatic bypass valve choice and adjustmentLesson 4Directional control: proportional directional valve types, spool dynamics, flow control and electrohydraulic interfacesThis part looks at proportional directional valves in 250-bar presses, covering types, spool movement, flow control, and electric-hydraulic links for exact motion, repeat accuracy, and safe stop actions.
Valve build and proportional control waysSpool shape, overlap, and flow control actionMovement response, delay, and shake methodsBuilt-in electronics, drivers, and signal rulesSafe stop positions and emergency plansLesson 5Filtration and contamination control: filter types, locations (suction, pressure, return), bypass and monitoringThis part deals with filter plans for high-pressure presses, covering filter types, ratings, and spots on suction, pressure, and return lines, plus bypass valves, block signs, and clean goals for long part life.
Clean target levels for press partsSuction screens vs low-pressure filtersHigh-pressure filter choice and sizeReturn line filters and extra clean unitsBypass valves and pressure difference signsLesson 6Energy storage and smoothing: accumulator types, placement, sizing and safety devicesThis part explains hydraulic accumulators for energy saving and pulse reduction, covering bladder, piston, and membrane types, position, pre-fill, size for press cycles, and safety tools as per rules.
Accumulator types and build detailsEnergy save calculations for press cyclesPre-fill pressure choice and checkPosition for pulse reduction and quick responseSafety blocks, shut valves, and rulesLesson 7Fluid circuits and schematic interpretation: common arrangements for forming presses, actuator piping, and bleed/vent pathsThis part builds full fluid systems for forming presses, teaching diagram signs, common press setups, actuator pipes, bleed and vent paths, and how to read, check, and record hydraulic plans for projects.
ISO hydraulic signs and line rulesCommon single- and double-action press systemsClamping, forming, and return stroke setupsBleed, vent, and air removal plansReading and checking full press diagramsLesson 8Power transmission elements: variable displacement axial piston pump principles and control interfacesThis part focuses on variable displacement axial piston pumps in 250-bar presses, explaining work principles, tilt plate control, balance options, and electric links that match flow, pressure, and energy saving.
Axial piston pump work principlesTilt plate systems and stroke controlPressure and load-sense control choicesElectric-hydraulic pump control linksStart, setup, and fix methodsLesson 9Pressure control components: relief valves, pressure compensators, sequence and unloading valvesThis part checks pressure control parts in press systems, including relief valves, pressure balancers, sequence valves, and unload valves, explaining settings, steadiness, links, and role in safety and energy saving.
Main system relief valve size and settingPump pressure balancer functions and adjustmentSequence valves for step cylinder workUnload valves for low-loss idle workLinks of many pressure control tools
